A Wire Twisting Machine (wire stranding machine) is specialized automation equipment used to twist single or multiple strands of wire into a unified, structured strand. It is widely applied in the wire and cable, electronics, automotive, and electrical manufacturing industries, playing a key role in improving wire conductivity, mechanical strength, and stability.
Its primary function is to twist discrete wires (such as copper, aluminum, tinned copper, enameled wire, or fiber optic conductors) into a single, integrated strand. The twisted structure enhances the wire’s performance—for example, reducing signal interference in communication cables or increasing load-bearing capacity in power cables.
- Wire & Cable Manufacturing: Stranding for power cables (0.6/1kV low-voltage to 110kV high-voltage), LAN cables (Cat5e/Cat6), automotive wiring harnesses, and coaxial cables.
- Electronics Industry: Twisting of enameled wire for motors/transformers, and flexible wire for connectors.
- Specialty Wire Processing: Production of braided wire, shielded wire, and medical-grade precision wire.
The operation of a wire twisting machine follows a "unified tension supply → synchronous twisting → stable traction → precise winding" workflow, driven by mechanical transmission and automated control. The core steps are as follows:
- Unwinding Mechanism: Raw wires are wound on multiple pay-off spools (the number depends on the required number of strands, e.g., 7-strand or 19-strand stranding). These spools are mounted on a rotating "pay-off turntable" or fixed pay-off frames.
- Tension Regulation: Each pay-off spool is equipped with a tension control device (e.g., magnetic powder brake, dancer arm, or damping wheel) to ensure consistent tension across all wires. Unstable tension causes uneven twisting or wire breakage.
This is the key link, and the twisting method varies by machine type (see Section 3 for classifications). The core principle is to use a rotating mechanism to drive the wires to spiral around a central axis:
- Twisting Drive: A servo motor or variable-frequency motor drives a "twisting bow" (a U-shaped rotating component) or "twisting cage" (a multi-spindle turntable) via a reducer and synchronous belt.
- Strand Formation: As the twisting bow/cage rotates, the wires from the pay-off spools are pulled into the twisting zone, where they spiral around each other to form a stranded conductor. The rotation speed directly determines the "twist pitch" (distance between adjacent spirals)—higher speed = shorter pitch = tighter twist.
- Traction Mechanism: After twisting, the integrated strand is pulled forward by a pair of traction wheels (usually rubber-coated to avoid wire damage). The traction speed is synchronized with the twisting speed to prevent slack or stretching.
- Length Monitoring: An encoder is installed on the traction wheel to count its rotations. The system calculates the actual length of the stranded wire (based on wheel circumference × rotations) and triggers a cut or stop signal when the preset length is reached.
The twisted wire is evenly wound onto a take-up spool via a "traverse guide" (a reciprocating component that ensures the wire is neatly arranged without overlapping). The take-up spool is driven by a torque motor or servo motor, with speed adjusted to match the traction speed for stable winding.
- Sensors (e.g., wire breakage detectors, tension sensors, or overload switches) monitor the process in real time. If a wire breaks, tangles, or tension exceeds the threshold, the system immediately stops the machine and triggers an alarm to avoid equipment damage or defective products.
Machines are classified by structure and twisting method, each suited to different wire specifications and production needs:
Parameters directly affect the machine’s performance and applicable wire range. When selecting a machine, focus on the following:
